Monolithic 3D Printed Aircraft Structural Components
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The production of aircraft involves high outlay and weight due to the use of numerous individual parts with complex geometries and additional fixing means, as well as the need for separate installation spaces for aircraft systems.
Innovation Solution
The application of three-dimensional printing (3-D printing) to produce monolithic structural components that integrate aircraft systems directly into the structure, reducing the number of individual parts and enabling the absorption and transmission of forces while performing specific aircraft functions, such as aerodynamic and energy transmission tasks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional individual parts and fixing means are used to produce aircraft structures, then structural strength and assembly flexibility are maintained, but production outlay and overall weight increase significantly
Solution Approach 1:
The patent merges multiple individual structural parts (formers, stringers, skin regions) and aircraft systems (electric leads, hydraulic lines, actuators) into integrated monolithic structural components. These components are produced as single pieces using three-dimensional printing technology, eliminating the need for numerous separate parts and fixing means while maintaining structural strength and enabling direct integration of aircraft systems.
Solution Approach 2:
The monolithic structural components serve multiple functions simultaneously: they provide structural support, create installation spaces for aircraft systems, and integrate aircraft systems directly into the structure. This multi-functionality reduces the overall number of components needed while maintaining all necessary structural and system functions.
2Strength
If numerous individual parts and fixing means are used in aircraft production, then structural integrity is maintained, but the overall weight of the aeroplane increases considerably
Solution Approach 1:
By combining multiple structural elements into single monolithic components, the patent eliminates the weight of fixing means (rivets, pins, screws) and reduces the total material required. The integrated design removes redundant structural elements while maintaining structural integrity through optimized monolithic geometries produced by three-dimensional printing.
3Adaptability or versatility
If separate installation spaces are provided for aircraft systems, then system functionality is ensured, but production complexity and component quantity increase
Solution Approach 1:
The patent merges the structural components and installation spaces into single integrated monolithic parts. Aircraft systems are directly integrated into the structure during the three-dimensional printing process, eliminating the need for separate installation spaces and reducing production complexity.
Solution Approach 2:
The installation spaces for aircraft systems are built into the monolithic structural components during the three-dimensional printing process itself, before final assembly. This preliminary integration simplifies subsequent assembly operations and reduces the number of separate components that need to be installed.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach significantly reduces production complexity and weight by creating integrated installation spaces within the aircraft structure, allowing for fewer components and streamlined assembly processes.
Implementation Method 1
at least one monolithic structural component is produced by means of a three-dimensional printing method
Implementation Method 2
monolithic structural components, which are produced by 3-D printing, i.e. by 'laser additive manufacturing'
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3
AI summary
The present invention relates to an aircraft (100). The aircraft (100) has a primary structural element (10), which extends along a main axis (x, y) of the aircraft (100) and at least one monolithic structural component (11), which is produced by means of a three-dimensional printing method. The aircraft (100) furthermore has an aircraft system (20) for carrying out an aircraft-specific function. The at least one monolithic structural component (11) is fixed on the primary structural element (10) by a fixing means (30). The monolithic structural component (11) is embodied to accommodate the aircraft system (20). The invention furthermore relates to a method for producing an aircraft (100).